Method and apparatus for fastening slide fasteners to an article

ABSTRACT

A method and apparatus for ultrasonically welding a zipper to another material wherein the material to which the zipper is to be joined is first loaded into a movable anvil and clamped between the anvil and a cutting plate. A die then cuts the material against the cutting plate. After cutting against the plate, the punch overtravels and forces the edges of the material up vertically between the ends of two plates. Then a vacuum applied above the plates draws the edges of the material back over the ends of the plates and holds the edges of the material in place. The zipper is placed into a zipper nest above the edges of the material. An ultrasonic welding system then welds the zipper to the turned back edges of the material.

lite States Hofius, Sr.

atet [1 1 [451 May 2a, 1975 [76] Inventor: David V. Hofius, Sun, 235Pierce Ave., Sharpsvillc, Pa. 16150 [22] Filed: Apr. 8, 1974 [21] Appl.No.: 458,681

[52] US. Cl 156/73.1; 24/205.l1 F; 156/66; 156/256; 156/285; 156/513;156/51'7;

[51] Int. Cl. 1332b 31/20 [58] Field of Search l56/73.1, 580, 66, 256,156/513, 517, 285; 228/1; 264/69; 24/205.l1

[561 References Cited UNITED STATES PATENTS 3,001,904 9/1961 Porepp156/66 3,488,239 l/l970 Heimberger 24/205.l1 F

Primary Examiner-Edward G. Whitby {5 7] ABSTRACT A method and apparatusfor ultrasonically welding a zipper to another material wherein thematerial to which the zipper is to be joined is first loaded into amovable anvil and clamped between the anvil and a cutting plate. A diethen cuts the material against the cutting plate. After cutting againstthe plate, the punch overtravels and forces the edges of the material upvertically between the ends of two plates. Then a vacuum applied abovethe plates draws the edges of the material back over the ends of theplates and holds the edges of the material in place. The zipper. isplaced into a zipper nest above the edges of the material. An ultrasonicwelding system then welds the zipper to the turned back edges of thematerial.

14 Claims, 18 Drawing Figures PATENTED HAY 2 0 I975 SHEET w 4 METHOD ANDAPPARATUS FOR FASTENING SLIDE FASTENERS TO AN ARTICLE OBJECTS OF THEINVENTION It is an object of the invention to provide an improved methodand apparatus for attaching a zipper to a garment. I

Another object of the invention is to provide a simple and efficientmethod and apparatus for attaching a zipper to a garment.

With the above and other objects in view, the present invention consistsof the combination and arrangement of parts hereinafter more fullydescribed, illustrated in the accompanying drawings and moreparticularly pointed out in the appended claims, it being understoodthat changes may be made in the form, size, proportions, and minordetails of construction without departing from the spirit or sacrificingany of the advantages of the invention.

GENERAL DESCRIPTION OF THE DRAWINGS FIG. I is a partial lateral crosssectional view of an apparatus used for carrying out the methodaccording to the invention; I

FIG. 2 is a top view of thecloth after it has been slit by the upperedge of the knife as in FIG. 1;

FIG. 3 shows a partial cross sectional view of the machine showing thematerial after having been cut by the punch and the edges of thematerial pushed upward by the overtravel ofthe punch;

FIG. 4 shows a top view of the clothhaving its edges up by theovertravel of the punch as in FIG. 3;

FIG. 5 is a cross sectional view of the cloth after the ends are pushedup by the punch as in FIGS. 3 and 4, taken on line 55 of FIG. 4;

FIG. 6 shows a partial top view of the fixture;

FIG. 7 shows a partial lateral cross sectional view of the machine withthe punch retracted with the ends of the cloth drawn back over the edgesof thin support member and the zipper in the zipper nest in the slideplates;

FIG. 8 shows a partial cross sectional view of the material as it wouldappear removed from the machine in FIG. 7;

FIG. 9 shows a partial longitudinal cross sectionalview of the machinewith the zipper lowered onto the material and the ultrasonic head moveddown into engagement with the zipper material;

FIG. 10 shows a partial top view of the completed zipper welded to thematerial;

FIG. 11 shows a partial top view of the completed zipper welded to thematerial as in FIG. 10;

FIG. 12 is a view similar to FIG. 1 showing another embodiment of theinvention;

FIG. 13 is a view similar to FIG. 2 showing the embodiment of FIG. 12;

FIG. 14 is a view similar to FIG. 3;

FIG. 15 is a view similar to FIG. 9;

FIG. 16 is a partial view similar to FIG. 15;

FIG. 17 is a side view partly in cross section of the anvil; and

FIG. 18 is an end view of the anvil.

DETAILED DESCRIPTION OF THE DRAWINGS An example of the machine forcarrying out the method disclosed herein is shown in FIGS. 1 through 4.In this example, the machine is made up basically of a hollow movableanvil 12 with a punch 14 slidably re ceived therein attached to camfollower bar 33. Two vacuum plates 19 terminate in end 17 and twosliding plates 16 slide on top of the ridges defining slots 13 in ends17 of plates 19. Plates 16 each have transverse grooves 25 in the underside which connect the vacuum channel passages 18 to slots 13 in thevacuum plates 19.

The punch 14 terminates at its upper end in a cutting edge 15 which willbe in the shape of the slit 22 in the material 10 and branches 24connected to the slit 22 which are to be cut for the zipper in thematerial 10 to which the zipper is to be attached. When the punch hascut the slit 22 and branches 24 in the material, the sliding plates 16move away from each other to the position shown in FIG. 3 and the punch14 then moves up between the ends of the plates through the spacebetween the ends 17 of the vacuum plates 19; as the punch overtravels,it carries the cut edges 27 of the material up to the position shown inFIG. 3.

The sliding ends of top plates 16 engage each other at a position offsetfrom edge 15. The inner ends of top plates 16 are thin and form a zipperpocket 22"-in which the zipper can be placed when the plates are broughtto the position shown in FIG. 7 prior to lowering the zipper onto thematerial. I

The sliding top plate 16 on the right slides past center so that edge 15engages plate 16 at a position spaced from its end. Relatively closelyspaced slots 13 are formed in the top side of plates 19. The slots 13extend from the ends 17 of plates 19 adjacent ends to shoulders 41. Thegrooves 25 in plates 16 connect the vacuum passages 18 in vacuum plates19 to the slots 13 when the sliding ,top plates 16 are retracted to aposition shown in FIG. 3.'Thus when the cutting edge 15 of the punch 14crush .cuts the fabric material 10 against the bottom of the plate 16and plate 16 moves laterally aside and the punch overtravels to push theedges 27 I upward to the position shown in FIG. 3, the vacuum then pullsedges 27 of the material over the top of ends 17 of plates 19. Theplates 16 will then move toward each other and over the ends of thetapes 2] and forming the zipper pocket 22 in plates 16 as shown in FIG.7. The plates 16 will then be moved away from each other by the forcemeans indicated at 40 and the zipper 11 will drop onto the zippersupported on the end plates 17 as shown in FIG. 9. The ultrasonic head28 will be lowered into engagement with the tapes of the zipper by asuitable force means indicated by arrow 29. Ultrasonic energy will thenbe applied to the ultrasonic head 28 which will weld the edges 27 of thematerial to the zipper tape 21. The ends 27 will actually lie betweenplates 16 and plate ends 17 in the position shown I in FIG.- 7 since thematerial will be only about 0.020 inches thick.

Anvil 12 has an elongated body having spaced sides 84 and a bottom 85with open top 86. Anvil 12 is fixed to lug and is carried up and down bya force means 34 connected to lug 70 and the anvil may rock around thelug 70. Punch '14 is fixed to follower bar 33 which is guided up anddown on pins 71. Pins 71 are fixed to the sides of anvil 12 and extendacross it and pins 71 are received in slots 72 in the punch follower bar33. Follower bar 33 has the bracket 74 fixed to it and bracket 74carries the follower wheel 73. Plate 75 is fixed to the bottom of theanvil 12 and forms a sliding surface on which cam 76 slides. Cam 76 hasa top cam surface 77 that engages the wheel 73. Cylinder 78 moves thecam 76 forward and backward to raise and lower the follower bar andpunch. Cylinder 78 is connected to the anvil 12 and piston rod 79 isattached to the connecting rod 80 by means of pin 83. The connecting rod80 is likewise connected to the cam 76 by pin 81. The anvil 12 is movedup and down to clamp the material to the plate 16 and the punch is movedup and down by cylinder 78 through the cam 76 and follower wheel 73.Thus the anvil and the punch can rock around the lug 70 and the punchedge will engage the material to be cut over its entire length.

The sequence of operation of the embodiment shown in FIGS. 1-11 is asfollows:

Step 1. Sheet material 10 is loaded on anvil 12. Plates 16 are movedtogether to the position shown in FIG. 1.

Step 2. Anvil 12 moves up and clamps sheet material 10 to the under sideof plates 19.

Step 3. Punch 14 moves up and cuts slots 22-24 in material 10 againstthe lower side of plates 16.

Step 4. Plates 16 move apart from each other and punch 14 overtravelsand pushes edges 27 of material up to position shown in FIG. 3.

Step 5. Plates 16 move to position shown in FIG. 7, passing over theedges 27 of the material and slots 25 connect slot 22 with passages 18.Vacuum force from passages 18 through slots 25 and slots 13 pull ends 27of material 10 back over ends 17 of plates 19 as shown in FIG. 7. Zipper11 is placed in nest 22.

Step 6. Plates 16 are moved away from each other and zipper 11 movesdown onto top of plates 19. Ultrasonic head 28 descends into engagementwith zipper 11 and welds tapes of zipper to edges 27 of cloth.

Step 7. Ultrasonic head 28 moves up away from zipper 11, anvil 12 movesdown, plates 19 move outward away from each other and sheet material 10with zipper 11 attached can be removed.

FIGS. 12 through 16 show another embodiment of the invention similar tothe embodiment shown in FIGS. l-11. Vacuum plates 119 have reducedthickness ends 117 against which material 110 is clamped by anvil 112.Slots 113 in plates 119 are disposed at right angles to transverse slots125 and connect when the plates 116 are in the position shown in FIG.13. Hooks 145 on the ends of plates 116 grasp the edges 127 of thematerial 121 and pull the edges back to the position shown in FIG. 14prior to the descent of head 140. The hooks 145 thus supplement thevacuum. Punch 114 cuts the cloth against plates 116 as in FIG. 12. Withthe embodiment of FIGS. 12-16, the edges of the material are morepositively folded back by hooks 145.

The operation of the embodiment of FIGS. 12-16 is as follows:

Step 1. Sheet material 110 is loaded on anvil 112 between plates 116 andanvil 112.

Step 2. Anivl 112 moves up and clamps material 110 to plates ends and117.

Step 3. Punch 114 moves up and cuts slit in sheet material (FIG. 12)against hardened insert 116' in plate 116.

Step 4 Punch 114 overtravels and pushes edges 127 upward. Books 145catch edges 127 and, together with vacuum from passages 118 connected toslots 113 by grooves 125, pull cut edges 127 back (FIGS. l3, 14).

Step 5. Zipper 111 is loaded in nest formed by shoulders 146.

Step 6. Head lowers, bringing zipper 111 down between plates 116,pressing zipper 111 on edges 117 and is ultrasonically welded to thezipper tapes.

Referring to FIGS. 12-16, each sliding plate 116 is slidably supportedunder a bottom surface 162 on a fixed plate 160. The plates each have anend 161 spaced from the other and a bottom surface 162' which rests onthe top surface 163 of plates 119. Surface 168 is spaced above surface163 and provides a space for sliding plates 116. The hooks 145 on plates116 are each formed ofa slot 164 in the plate 116 and the surfaces 166are disposed at 45 to the vertical and these surfaces terminate in theedge of the hook which engages the material. The edges 167 of hooks 145are spaced above the top surface of plate 119 an amount equal to the sumof the thickness of the tape 121 and the material 110. Thus the edges167 of the hooks 145 hold the edges 127 of the material down during thewelding operation, as indicated in FIGS. 14 and 15.

The foregoing specification sets forth the invention in its preferredpractical forms but the structure shown is capable of modificationwithin a range of equivalents without departing from the invention whichis to be understood is broadly novel as is commensurate with theappended claims.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:

l. A method of ultrasonically welding a zipper to a sheet of materialcomprising die cutting a slot in said material,

folding the edges of said material back adjacent said slot,

placing the tapes of the zipper on top of said folded back edges,

and ultrasonically welding said zipper to said folded back edges.

2. A method of attaching a zipper to another material by ultrasonicwelding comprising a. loading the material to which the zipper is to bejoined onto a movable clamping anvil,

b. clamping the material against two spaced vacuum plates,

c. die cutting a slit in the clamped material against said slidingplates,

(1. moving said sliding plates apart,

e. pushing the edges of said material adjacent said slit between saidvacuum plates by punch overtravel,

f. applying a vacuum to the cut edges of said material to turn the edgesof said material back over on said vacuum plates,

g. moving the upper slide plate laterally thereby opening up slotsin thetop side of the plate,

h. loading a zipper in said machine,

i. welding the zipper to the edges ultrasonically.

3. An apparatus for ultrasonically welding a zipper to a sheet ofmaterial comprising two spaced vacuum plates defining a slot,

laterally extending slots in the top surface of said vacuum platesextending from adjacent the ends thereof.

two sliding plates, one said sliding plate slidable laterally on top ofeach of said vacuum plates from a position where the ends of saidsliding plates are adjacent each other to a position spaced further fromeach other,

means for connecting said slots in said vacuum plates to a vacuumchannel,

a source of vacuum connected to said vacuum channel,

a punch,

an anvil below said vacuum plates adapted to clamp said sheet materialto said vacuum plates,

said punch being slidably received in said anvil,

and means connected to said punch to move said punch into engagementwith a said sliding plate when said plate is slid over said top of saidpunch whereby a slit may be cut in said sheet material, means on saidvacuum plates to receive the edges of said cut material with a zipper ontop thereof, and an ultrasonic head above said anvil adapted to movedown into engagement with said zipper, clamping said zipper inengagement with said anvil, and means connected to said ultrasonic headfor ultrasonically welding said zipper to said material.

4. The apparatus recited in claim 3 wherein said sliding plates areadapted to slide toward each other to bring the ends into engagementwith each other at a position spaced laterally from the cutting edge ofsaid punch whereby said punch engages said material at a position spacedfrom the edge of one said sliding plate.

5. The apparatus recited in claim 4 wherein said punch has a cuttingedge generally of a length equal to the length of the zipper to beinstalled in said material.

6. The apparatus recited in claim 5 wherein said punch has an elongatedcutting edge and two branches whereby an end of said slit is cut in theshape of a Y.

7. The apparatus recited in claim 6 wherein said sliding plates eachhave a hook formed on the end thereof adjacent the other sliding plate,providing a hold down and aid in folding of the edges of said material.

8. The apparatus recited in claim 7 wherein said punch has awedge-shaped upper end terminating in said cutting edge.

9. The apparatus recited in claim 8 wherein said sliding plate has ahardened insert adjacent said hook en- 6 gagable by said cutting edge.

10. The apparatus recited in claim 9 wherein said hooks are each definedby slots in each said sliding plate adjacent the end thereof,

the end of said hook is spaced above said vacuum plate by an amountsubstantially equal to the thickness of said material plus the thicknessof the tape on said zipper to be installed on said material.

11. An apparatus for ultrasonically welding a zipper to a sheet ofmaterial comprising a movable top plate,

a vacuum plate terminating at an edge,

a plurality of slots in said vacuum plate extending from said edge to aposition spaced from said edge, said movable top plate supported abovesaid vacuum plate and movable thereover,

a punch,

said punch having an elongated cutting edge adapted to engage said topplate,

meansfor moving said punch into engagement with said top plate,

said means comprising a single force applied to said punch whereby saidpunch will rock about said force and engage said plate over the entirelength of said punch.

12. The apparatus recited in claim 11 wherein said punch is carried byan anvil,

said anvil extending laterally from said punch on each side thereof,

and means to move said punch relative to said anvil whereby said anvilmay be brought into clamping engagement with said material and clampingsaid material to said vacuum plate,

and said punch may be brought into engagement with said material,cutting said material against said top plate.

13. The apparatus recited in claim 12 wherein means is provided formoving said top plate in a plane parallel to said vacuum plate wherebyan edge of said material may be pulled over said vacuum plate.

14. The apparatus recited in claim 13 wherein ultrasonic means isprovided for engaging said material above said vacuum plate.

1. A method of ultrasonically welding a zipper to a sheet of materialcomprising die cutting a slot in said material, folding the edges ofsaid material back adjacent said slot, placing the tapes of the zipperon top of said folded back edges, and ultrasonically welding said zipperto said folded back edges.
 2. A method of attaching a zipper to anothermaterial by ultrasonic welding comprising a. loading the material towhich the zipper is to be joined onto a movable clamping anvil, b.clamping the material against two spaced vacuum plates, c. die cutting aslit in the clamped material against said sliding plates, d. moving saidsliding plates apart, e. pushing the edges of said material adjacentsaid slit between said vacuum plates by punch overtravel, f. applying avacuum to the cut edges of said material to turn the edges of saidmaterial 180* back over on said vacuum plates, g. moving the upper slideplate laterally thereby opening up slots in the top side of the plate,h. loading a zipper in said machine, i. welding the zipper to the edgesultrasonically.
 3. An apparatus for ultrasonically welding a zipper to asheet of material comprising two spaced vacuum plates defining a slot,laterally extending slots in the top surface of said vacuum platesextending from adjacent the ends thereof, two sliding plates, one saidsliding plate slidable laterally on top of each of said vacuum platesfrom a position where the ends of said sliding plates are adjacent eachother to a position spaced further from each other, means for connectingsaid slots in said vacuum plates to a vacuum channel, a source of vacuumconnected to said vacuum channel, a punch, an anvil below said vacuumplates adapted to clamp said sheet material to said vacuum plates, saidpunch being slidably received in said anvil, and means connected to saidpunch to move said punch into engagement with a said sliding plate whensaid plate is slid over said top of said punch whereby a slit may be cutin said sheet material, means on said vacuum plates to receive the edgesof said cut material with a zipper on top thereof, and an ultrasonichead above said anvil adapted to move down into engagement with saidzipper, clamping said zipper in engagement with said anvil, and meansconnected to said ultrasonic head for ultrasonically welding said zipperto said material.
 4. The apparatus recited in claim 3 wherein saidsliding plates are adapted to slide toward each other to bring the endsinto engagement with each other at a position spaced laterally from thecutting edge of said punch whereby said punch engages said material at aposition spaced from the edge of one said sliding plate.
 5. Theapparatus recited in claim 4 wherein said punch has a cutting edgegenerally of a length equal to the length of the zipper to be installedin said material.
 6. The apparatus recited in claim 5 wherein said punchhas an elongated cutting edge and two branches whereby an end of saidslit is cut in the shape of a Y.
 7. The apparatus recited in claim 6wherein said sliding plates each have a hook formed on the end thereofadjacent the other sliding plate, providing a hold down and aid infolding of the edges of said material.
 8. The apparatus recited in claim7 wherein said punch has a wedge-shaped upper end terminating in saidcutting edge.
 9. The apparatus recited in claim 8 wherein said slidingplate has a hardenEd insert adjacent said hook engagable by said cuttingedge.
 10. The apparatus recited in claim 9 wherein said hooks are eachdefined by slots in each said sliding plate adjacent the end thereof,the end of said hook is spaced above said vacuum plate by an amountsubstantially equal to the thickness of said material plus the thicknessof the tape on said zipper to be installed on said material.
 11. Anapparatus for ultrasonically welding a zipper to a sheet of materialcomprising a movable top plate, a vacuum plate terminating at an edge, aplurality of slots in said vacuum plate extending from said edge to aposition spaced from said edge, said movable top plate supported abovesaid vacuum plate and movable thereover, a punch, said punch having anelongated cutting edge adapted to engage said top plate, means formoving said punch into engagement with said top plate, said meanscomprising a single force applied to said punch whereby said punch willrock about said force and engage said plate over the entire length ofsaid punch.
 12. The apparatus recited in claim 11 wherein said punch iscarried by an anvil, said anvil extending laterally from said punch oneach side thereof, and means to move said punch relative to said anvilwhereby said anvil may be brought into clamping engagement with saidmaterial and clamping said material to said vacuum plate, and said punchmay be brought into engagement with said material, cutting said materialagainst said top plate.
 13. The apparatus recited in claim 12 whereinmeans is provided for moving said top plate in a plane parallel to saidvacuum plate whereby an edge of said material may be pulled over saidvacuum plate.
 14. The apparatus recited in claim 13 wherein ultrasonicmeans is provided for engaging said material above said vacuum plate.